Fixed Cutter Drill Bit With Pressure Intensifier
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Solution Overview
Problem
Conventional drilling systems face challenges in efficiently removing material from formations without increasing mechanical force, which can lead to bit erosion and reduced reliability and operational lifetime due to high fluid pressures.
Innovation Solution
A drill bit design incorporating a pressure intensifier that supplies high-pressure fluid through a high-pressure fluid channel with erosion-resistant nozzles, combined with a low-pressure fluid channel for debris removal, reducing mechanical force requirements and enhancing bit durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high fluid pressure is used to remove material from the formation, then the rate of penetration is improved, but the bit erosion increases and reliability decreases
Solution Approach 1:
The bit is divided into multiple functional zones: a fluid jetting portion with high-pressure nozzles for material removal, a fixed cutter portion for mechanical cutting, and a gauge portion for hole cleaning. This segmentation allows each zone to perform its specific function optimally without the entire bit being subjected to high erosion risks.
Solution Approach 2:
Different portions of the bit are assigned different properties and functions. The fluid jetting portion uses high-pressure fluid jets for efficient material removal, while the fixed cutter portion uses mechanical cutting elements for robust material removal. The gauge portion uses low-pressure fluid for cuttings removal. This local differentiation allows high-pressure fluid jets to be used only where most effective, minimizing overall erosion.
2Productivity
If mechanical force is increased to remove material from the formation, then the rate of penetration is improved, but the torque and weight on bit requirements increase
Solution Approach 1:
The patent replaces purely mechanical cutting with a hybrid system that incorporates high-pressure fluid jets. The fluid jets perform material removal through hydraulic action, cavitation, and erosion mechanisms, substituting for some of the mechanical force that would otherwise be required from the cutters and reducing the torque and weight on bit requirements.
Solution Approach 2:
The patent uses high-pressure fluid hydraulics to remove material from the formation. The fluid is pumped at high pressure through nozzles in the fluid jetting portion of the bit, creating high-velocity jets that erode and remove formation material, thereby reducing the mechanical force needed compared to conventional mechanical bits.
3Device complexity
If conventional mechanical bits are used to remove material, then the system is simple, but the mechanical force requirements increase and operational lifetime decreases
Solution Approach 1:
The bit combines multiple functions in a single downhole tool: high-pressure fluid jetting for material removal, mechanical cutting with fixed cutters, and hole cleaning with the gauge portion. This multi-functionality allows the system to achieve both high productivity and extended operational lifetime without requiring multiple separate tools, maintaining relative system simplicity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution increases the rate of penetration while minimizing the likelihood of bit failure, maintaining reliability and extending the operational lifetime by effectively using high-pressure fluid jets for material removal without adverse effects on the bit.
Implementation Method 1
The pressure intensifier is configured to increase a pressure of a fluid and supply the fluid to the high-pressure fluid channel in the bit body
Implementation Method 2
A high-pressure fluid channel is in the bit body and exits the fluid jetting portion of the bit body. At least one high-pressure nozzle is coupled to the fluid jetting portion of the bit body and is in fluid communication with the high-pressure fluid channel
Data Source
Figure 1
Figure 2-1
Figure 2-2
AI summary
A drill bit includes a bit body with high and low fluid pressure bodies. The low-ressure bit body includes a fixed cutting structure, and the high-pressure bit body includes at least one high-pressure fluid channel and nozzle capable of withstanding fluid pressures greater than 40 kpsi (276 MPa). A bottomhole assembly includes a drill bit with a bit body having fixed cutter and fluid jetting portions. Low and high-pressure channels in the bit body exit in the fixed cutter and fluid jetting portions. A high-pressure nozzle is coupled to the fluid jetting portion and the high-pressure fluid channel, and a plurality of fixed cutting elements are coupled to the fixed cutter portion. A pressure intensifier is coupled to the drill bit and is configured to increase a pressure of a fluid supplied to the high-pressure fluid channel in the bit body.